Coke oven reconstruction

Abstract

A new, faster and more efficient process to replace heating walls and ceilings in coke oven batteries. Thus, when replaced, at least one heating wall is constructed of thermally stable non-expanding large size modular cast modules from end to end and the ceiling adjacent the heating wall is constructed of thermally stable non-expanding large modular cast blocks.

1. A method of reconstructing a heating wall of a coking chamber in a coke oven battery from one end of the chamber to an opposite end, comprising:
 a) laying a course of large size cast modules using thermally stable, non-expanding large size modular cast modules, each module having at least one vertical opening which defines a portion of a flue; 
 b) on a first course of large size cast modules, setting proper measurements between the large size cast modules and existing heating walls to insure proper taper of the oven; 
 c) leveling and aligning the course of large size cast modules using at least one of story poles and levels; 
 d) mortaring the large size cast modules into place; 
 e) repeating steps (a), (c), and (d) to install subsequent layers of large size cast modules to create a newly laid heating wall; 
 f) laying a plurality of courses of thermally stable, non-expanding large size modular cast ceiling blocks on the top of adjacent heating walls, at least one of the adjacent heating walls being the newly-laid heating wall, the cast ceiling blocks including (i) flue ceiling blocks stacked from a top of each wall to a top of a ceiling thereby extending the flue through the ceiling and (ii) second ceiling blocks stacked from the top of each wall to the top of the ceiling, defining passageways through the ceiling from the coking chamber bounded by the adjacent heating walls, each of the second ceiling blocks being wider than the distance between the adjacent heating walls; 
 g) mortaring the large size cast ceiling blocks into place; and 
 h) pouring a top cover between the flue ceiling blocks and the second ceiling blocks to complete the ceiling. 
 
     
     
       2. The method as set forth in  claim 1  further comprising staggering each of the subsequent courses of large size cast modules from a course immediately below so seams between the large size cast modules in each course do not vertically align with seams between the large size cast modules in the course immediately below. 
     
     
       3. The method as set forth in  claim 1  in which vertically extending flues are formed by aligning the vertical openings of large size cast modules in each of the first course and subsequent layers, which flues may be used alternately for burning fuel gases or for drafting. 
     
     
       4. The method as set forth in  claim 1  in which prior to step (a) existing walls are demolished with heavy equipment or machinery. 
     
     
       5. The method as set forth in  claim 1  in which air ports in a floor of the oven are vacuumed out with heavy duty vacuuming equipment prior to step (a). 
     
     
       6. The method as set forth in  claim 1  in which gas nozzles and air ports in a floor upon which the heating wall is to be reconstructed are covered over with at least one of a heavy paper and an aluminum sheet prior to step (a). 
     
     
       7. The method as set forth in  claim 1  in which an interior of the oven is measured prior to fabrication of the large size cast modules, and the large size cast modules are custom made based on the measurements taken. 
     
     
       8. The method as set forth in  claim 1  in which secondary air stacks are installed as the first course and a first of the subsequent layers are laid. 
     
     
       9. The method as set forth in  claim 1  in which plugs are cut out of the first course of large size cast modules to form clean-out ports, and the plugs are mortared back into place to plug the clean-out ports before the heating walls are completely reconstructed. 
     
     
       10. A method of replacing a coke oven ceiling comprising:
 laying a plurality of thermally stable, modular non-expanding large size cast ceiling blocks on the top of adjacent heating walls, the cast ceiling blocks including (i) flue ceiling blocks stacked from a top of each wall to a top of a ceiling extending a vertical flue in one of the adjacent heating walls through the ceiling and (ii) second ceiling blocks stacked from the top of the adjacent heating walls to the top of the ceiling, defining passageways through the ceiling from a coking chamber bounded by the adjacent heating walls, each of the second ceiling blocks being wider than the distance between the adjacent heating walls; 
 mortaring the large size cast blocks into place; 
 pouring a castable material in a space between the flue ceiling blocks and the second ceiling blocks to complete the ceiling. 
 
     
     
       11. The method of replacing a coke oven ceiling as set forth in  claim 10  in which the passageways are one or more of a passageway to a standpipe, an aperture for a smoke hole, and an aperture for charging the coking chamber.